Conveying and alignment nozzle

ABSTRACT

A nozzle system that includes an improved air nozzle is provided. In one embodiment, the nozzle has an inlet and an outlet. An air source is connected with the nozzle through a conduit and generates an air flow using a high flow centrifugal blower. The nozzle is connected with and part of an air-driven orientation device.

CROSS REFERENCES TO RELATED APPLICATIONS

The Present application is a divisional of U.S. Non-Provisional patentapplication Ser. No. 13/481,272, filed May 25, 2012, which claims thebenefit of priority from U.S. Provisional Patent Application Ser. No.61/494,760, entitled “CONVEYING AND ALIGNMENT NOZZLE” and filed on Jun.8, 2011 with the United States Patent and Trademark Office, the contentsof all of which are hereby incorporated by reference in their entiretyto the extent permitted by law.

FIELD OF THE INVENTION

The present invention relates generally to processes and devices forfluid discharge. More specifically, it relates to nozzles through whicha supply of air is used to convey and align articles.

BACKGROUND

A variety of systems transfer fluids from a fluid supply source to oneor more fluid discharge devices. In some systems, an arrangement offluid conduits, which may include metal pipes, plastic pipes, and/orhoses, may provide a flow path for routing, channeling, or otherwisedelivering a fluid from a fluid supply source to a fluid dischargedevice, such as a nozzle. In the case of a nozzle, air received via aninlet may be pressurized and directed through the nozzle. The output ofthe nozzle may be utilized for a variety of applications, such as toposition, convey or align an article.

SUMMARY

The present invention is defined by the following claims, and nothing inthis section should be taken as a limitation on those claims.

In one aspect, an air-driven orientation device is provided. The deviceincludes, but is not limited to an air supply source including a highflow centrifugal blower for generating a low-pressure air flow, aconduit having an inlet coupled with an outlet of the air supply source,and a nozzle. The nozzle has an inlet coupled with an outlet of theconduit. The nozzle comprises a nozzle body having a nozzle inlet, anozzle outlet, and an annular wall defining a first passage that extendsthrough the nozzle body and which couples the nozzle inlet to the nozzleoutlet. The nozzle is capable of receiving the low pressure air flowfrom the air supply source at a first velocity and outputting an airflow having a second velocity which is 4 to 16 times greater than thefirst velocity.

In one aspect, method for orienting articles which travel along anassembly path within an air-driven orientation device is provided. Themethod includes, but is not limited to, generating a low-pressure airflow using a high flow centrifugal blower, transmitting the low-pressureair flow through a conduit and to a nozzle, receiving the low pressureair flow at a first velocity at the nozzle inlet, and generating andoutputting an air flow having a second velocity at the nozzle outletwhich is 4 to 16 times greater than the first velocity. The nozzle hasan inlet coupled with an outlet of the conduit. The nozzle comprises anozzle body having a nozzle inlet, a nozzle outlet, and an annular walldefining a first passage that extends through the nozzle body and whichcouples the nozzle inlet to the nozzle outlet.

In one aspect, an air-driven orientation device is provided. The deviceincludes, but is not limited to, an air supply source including a highflow centrifugal blower for generating a low-pressure air flow throughan outlet of the air supply source and a nozzle. The nozzle has an inletcoupled with an outlet of the air supply source. The nozzle comprises anozzle body having a nozzle inlet, a nozzle outlet, and an annular walldefining a first passage that extends through the nozzle body and whichcouples the nozzle inlet to the nozzle outlet. The nozzle is capable ofreceiving the low pressure air flow from the air supply source at afirst velocity and outputting an air flow having a second velocity whichis 4 to 16 times greater than the first velocity.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a simplified block diagram depicting a fluid-based system thatincludes one or more nozzles having nozzles, in accordance withembodiments of the present disclosure;

FIG. 2 is a simplified block diagram depicting a fluid-based system thatincludes one or more nozzles having nozzles, in accordance withembodiments of the present disclosure;

FIG. 3A is a side view of a nozzle which may be used in connection withthe system shown in FIGS. 1 and 2, connected with an elongatedcylindrical shaft, in accordance with embodiments of the presentdisclosure;

FIG. 3B is a front view of a nozzle which may be used in connection withthe system shown in FIGS. 1 and 2, connected with an elongatedcylindrical shaft, in accordance with embodiments of the presentdisclosure;

FIG. 3C is a side view of the elongated cylindrical shaft which is to beconnected with the nozzle shown in FIG. 3A, in accordance withembodiments of the present disclosure;

FIG. 3D is a side view of a nozzle shown in FIG. 3A, in accordance withembodiments of the present disclosure;

FIG. 3E is a front view of the nozzle shown in FIG. 3D, in accordancewith embodiments of the present disclosure;

FIG. 3F is a cross sectional view taken along line A-A of the nozzleshown in FIG. 3D, in accordance with embodiments of the presentdisclosure;

FIG. 4 is a more detailed view of the embodiment of the nozzle shown inFIG. 3A, in accordance with embodiments of the present disclosure;

FIG. 5 is a cross-sectional view of the nozzle of FIG. 3A connected witha conduit, showing the flow of air through one of the nozzles;

FIG. 6 is another cross-sectional view of the nozzle of FIG. 3Aconnected with a conduit, showing the flow of air through one of thenozzles;

FIG. 7 is an enlarged cross-sectional view of an embodiment of thenozzle taken along cut-line 7-7 of FIG. 4;

FIG. 8 is a perspective view of a fluid-based system that includes oneor more nozzles having nozzles, in accordance with embodiments of thepresent disclosure; and

FIG. 9 is a simplified block diagram depicting a fluid-based system thatincludes one or more nozzles having nozzles, in accordance withembodiments of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. Thesedescribed embodiments are provided only by way of example, and do notlimit the scope of the present disclosure. Additionally, in an effort toprovide a concise description of these exemplary embodiments, allfeatures of an actual implementation may not be described in thespecification. It should be appreciated that in the development of anysuch actual implementation, as in any engineering or design project,numerous implementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments described below, thearticles “a,” “an,” and “the” are intended to mean that there are one ormore of the elements. The terms “comprising,” “including,” and “having”are intended to be inclusive and mean that there may be additionalelements other than the listed elements. Moreover, while the term“exemplary” may be used herein in connection to certain examples ofaspects or embodiments of the presently disclosed subject matter, itwill be appreciated that these examples are illustrative in nature andthat the term “exemplary” is not used herein to denote any preference orrequirement with respect to a disclosed aspect or embodiment.Additionally, it should be understood that references to “oneembodiment,” “an embodiment,” “some embodiments,” and the like are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the disclosed features.

As discussed in further detail below, various embodiments of anorientation system that includes improved air nozzles are provided. Inone embodiment, a system includes an orientation device that employs adevice which generates low pressure air, such as a blower, to a nozzleused to position, convey, or align an article. The nozzle may be alignedwith respect to a path formed by the orientation system. The inlet ofthe nozzle may be shaped to conform to the outer surface of a fluidconduit. This reduces the need for additional fasteners and thus reducesmanufacturing and/or assembly time and costs.

The nozzle includes a variable section and a resistive section. Thevariable section extends from the nozzle inlet to an intermediatetransition point along the length of the nozzle, and has a converginginside diameter, which allows for an air flow entering the nozzle fromthe main body to compensate for flow losses due to cornering as the airflow enters the nozzle inlet. The resistive section extends from thetransition point to the nozzle outlet and has a generally constantdiameter which is less than the inside diameter of the variable sectionmeasured at the nozzle inlet. The resistive section thus resists andcontrols the flow of the air being discharged from the nozzle outlet. Inaccordance with aspects of the disclosure, the length of the resistivesection is less than the length of the variable section. The foregoingdesign, which is discussed in detail below, compensates for air flowlosses, and thereby improves overall air flow through the nozzle andincreases the energy efficiency of the orientation system.

Turning now to the drawings, FIG. 1 illustrates a processing system 10that may incorporate one or more aspects of the presently disclosedtechniques. The processing system 10 includes an air supply source 12that may deliver a fluid (e.g., air) to nozzles 42 along a flow path 16.In the illustrated embodiment, the flow path 16 includes the fluidconduits 20, 22, 26, 36, and 38, the adapters 24 and 28, and the divider32.

In the presently illustrated system 10, the air supply source 12 mayinclude a high flow centrifugal blower (“air blower”), such as a Paxton™Model XT300 Blower (Part Number 8006100) having 3 Hp and operating at 60Hz, 230V/460V/3/60 Hz at 160 CFm at 40″ w/c (pressure) and a Paxton™Enclosure, (Part Number 8006300), all manufactured by ITW Air Managementof Cincinnati, Ohio. In some embodiments, the air supply source 12 mayinclude a supercharger and motor configuration. In one embodiment, theoperating characteristics of the air blower 12 may provide alow-pressure air flow having a pressure of between approximately 1-10pounds per square inch (psi) and having a flow rate of betweenapproximately 50-2000 cubic feet per minute (CFM) or more specifically,between approximately 150 to 1500 CFM. In some embodiments, the airblower 12 may be housed within an enclosure. The air blower 12 may beseparated from the nozzles 42 by a distance of 10, 20, 30, 40, 50, 100,or 200 feet or more. As such, the flow path 16 is configured to providea path through which air provided by the air blower 12 may be routed andultimately delivered to the nozzles 42.

The air blower 12 may include an outlet 18 coupled to the fluid conduit20 that defines a first portion of the flow path 16. The fluid conduit20 may be coupled to the downstream fluid conduit 22 by way of a firstadapter 24. By way of example only, the fluid conduit 20 may be a hose,such as a flexible hose, and the fluid conduit 22 may be a pipe, such asa stainless steel pipe or a polyvinyl chloride (PVC) pipe. The adapter24 may be configured to provide an interface for coupling the hose 20and pipe 22. For instance, the adapter 24 may include a first adapterend configured to couple to the hose 20, and a second adapter endconfigured to couple to the pipe 22. In this manner, the hose 20,adapter 24, and pipe 22 are fluidly coupled, thereby allowing airdischarged from the outlet 18 of the blower 12 to flow from the hose 20into the pipe 22.

The flow path 16 continues to the distal end of the pipe 22, which maybe coupled to another hose 26 by way of a second adapter 28 that may besimilar in design to the first adapter 24. Thus, by way of the adapters24 and 28, the air flow from the blower 12 may be received by an inlet30 of a flow divider 32. The flow divider 32 may be configured todistribute or split the air flow to multiple outlets 33 and 34. In oneembodiment, the flow divider 32 is a Paxton™ Model 8005502-3-3 Dividermanufactured by ITW Air Management of Cincinnati, Ohio. In oneembodiment, the fluid conduits 20, 22, and 26 are a polyvinyl chloride(PVC) pipe having a diameter from 50 mm to 102 mm and preferably ofabout 77 mm, and the fluid conduits 36 and 38 are a polyvinyl chloride(PVC) pipe having a diameter from 25 mm to 77 mm and preferably of about50 mm.

Additional fluid conduits 36 and 38 may respectively couple the outlets33 and 34 to the nozzles 42, respectively. In the illustratedembodiment, the nozzles 42 may each include an inlet (72A and 72B)configured for a hose connection and the fluid conduits 36 and 38 maythus be provided as hoses, such as flexible hoses. In other embodiments,a pipe may be disposed between the divider 32 and one of the nozzles 42,whereby adapters similar to the above-discussed adapters 24 or 28 arecoupled to each end of the pipe to facilitate a fluid connection betweenhoses extending from an outlet (e.g., 33 or 34) of the divider 32 andfrom an inlet (e.g., 72A or 72B) of one of the nozzles (e.g., 42). Insome embodiments, the system 10 may include only a single nozzle (e.g.,42) and thus may not include a divider 32. In such embodiments, thefluid conduit 26 may be coupled directly to the nozzle 42.

As will be discussed further below, the nozzle 42 may include a mainbody or housing that defines a plenum or fluid cavity for receiving anair flow via the inlet 72. In certain embodiments, the nozzle 42 may beformed of materials including aluminum, stainless steel, plastic orcomposite materials, or some combination thereof. In some embodiments,the main body may be generally cylindrical in shape and may include oneor more openings which provide a path for air to flow into respectivenozzles 42 coupled to the main body of the nozzle.

In operation, the fluid cavity defined by the main body of the nozzle 42may pressurize and discharge air received via the inlet 72 through thenozzle(s) 42, as indicated by the output air flow 44. Accordingly, theair flow 44 exiting the nozzle(s) 42 may have a velocity that is greaterthan the velocity of the air flow entering via the inlet 72. While onlytwo outlets 33 and 34 are shown in FIG. 1, it should be appreciated thatthe flow divider 32 may be configured to provide any suitable number ofoutlets, and may provide flow paths to any suitable number of devices,such as additional nozzles, air knives, flow dividers, and so forth. Aswill be discussed further below, the nozzle 42, as designed inaccordance with embodiments of the present disclosure, may provide forimproved air flow by reducing losses due to cornering as air flows oversharp corners, such as the interface between the main body or housing ofthe nozzle 42 and the inlet of the nozzle 42.

As shown in FIG. 1, the air flows 44 exiting the respective nozzles 42of each of the nozzles 42 may be directed towards the applications 48and 50, respectively, of the processing system 10. For instance, theapplications 48 and 50 may be transported through the system 10 along aconveyor belt 52 or some other suitable type of transport mechanism. Aswill be appreciated, the application represented by the system 10 mayutilize the air flows 44 provided by the nozzles 42, respectively, for avariety of functions, including but not limited to drying products,removing dust or debris, coating control, cooling, leak detection,surface impregnation, corrosion prevention, and so forth. For instance,in certain embodiments, the system 10 may be a system for drying food orbeverage containers, such as cans or bottles, or may be a system forremoving dust and other debris from sensitive electronic products, suchas printed circuit boards (PCBs) or the like. In addition, someembodiments of the system 10 may also utilize the air flows 44 to cleanand/or remove debris from the conveyer belt 52.

With reference to FIGS. 2 and 9, in one embodiment, the system 10utilizes the air flows 44 to position, convey, or align articles 110within an air-driven orientation device 200. An air-driven orientationdevice 200 is any device capable of orientating an article 110 using anair flow 44, such as a vibratory bowl, a feeder, a sorter, an assemblyline, a conveyor belt, or an orientator. Articles 110 includes any typeof device which is manufactured, which makes up an item, and which needsto be aligned during assembly or manufacture of the item. Articles 110are preferably light enough to be orientated using a puff of air, suchas plastic articles like bottle caps or lids which need to be orientatedbefore being mated with a bottle. The oriented articles 110 follow anassembly path 57 down through the orientation device 200 to a conveyorline 120. Oriented articles 110 are driven down the conveyor line usinga pneumatic conveyor 130 which is driven by an air source 130, such as ahigh flow centrifugal blower (“air blower”). The oriented articles 110then enter a machine 140, which relies on the corrected orientation ofthe articles 110 to perform a task, such as to connect the articles 110with another part to form an item. For example, if the articles arebottle caps, the machine 140 may connect the bottle caps with a bottleto form a sealed bottle. The machine 140 may include devices, such as apneumatic cylinder 150, to perform a task.

As shown, the system 10 may include a number of nozzles 42A-42Fpositioned strategically about the orientation device 200 in order toorient articles 110 which travel along an assembly path 57 within theorientation device 200. As will be discussed below with respect to FIG.9, the conduits 36 and 38 may be connected with a number of additionalfluid conduits 36A-E and 38A-E, each of which corresponds to arespective one of the nozzles 42A-42J. The inlet ends of the nozzles42A-42J may be connected with or welded to each respective fluid conduit36A-E and 38A-E via TIG welding, as mentioned above, or via any othersuitable type of welding technique. In particular, the inlet ends of thenozzles 42A-42J may be welded to the outlets of each fluid conduit 36A-Eand 38A-E. Additionally, each fluid conduit 36A-E may be coupled withfluid conduit 36 via adapters 25A-E, respectively, and each fluidconduit 38A-E may be coupled with fluid conduit 38 via adapters 27A-E,respectively.

While the depicted embodiment of FIG. 9 shows ten nozzles (42A-42J), itshould be appreciated that various embodiments may provide any suitablenumber of nozzles. For instance, certain embodiments may include 2 to 20nozzles or more. The nozzles 42A-42J may be spaced apart along theassembly path 57 of the system 10, such that each nozzle 42A-42J isseparated by a distance 66 along the assembly path 57. The distance 66,in some embodiments may be between approximately 1 to 12 inches (e.g.,1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 7, 8, 9, 10, 11, or 12inches). In other embodiments, the distance 66 may be determined as apercentage of the total length of the path 57. By way of example, incertain embodiments, the distance 66 may be between approximately 10 to30 percent or, more specifically, between approximately 15 to 25 percentof the length of the path 57. In further embodiments, the distance 66may be different between each nozzle 42A-42F. For instance, in oneembodiment, the distance 66 may progressively increase or decrease fromone end of the path 57 to another end of the path 57.

As discussed with reference to FIG. 9, each of the nozzles 42A-42J mayhave an inlet end and an outlet end. For instance, as shown in FIG. 4,the nozzle 42 has an inlet 72 and an outlet 74. FIG. 4 depicts anenlarged view of an embodiment of the nozzle 42. As shown in theillustrated embodiment, the inlet 72 of the nozzle 42 may be formed orshaped to include a radius, such that the inlet 72 conforms to the outersurface of the generally cylindrical conduit 38 to which the nozzle 42is joined. That is, the shape of the inlet 72 conforms or fits flushagainst an outer surface of the conduit 38. As will be appreciated, thisimproves the ease of welding the nozzle 42 to the conduit 38 of thenozzle 42, and thereby reduces manufacturing time and costs. In otherembodiments, the nozzle 42 may be joined to a main body having anopening formed on a flat surface and, therefore, may not include theradius cut on the inlet 72.

FIGS. 5 and 6 show cross-sectional views of the nozzle 42. FIGS. 5 and 6will generally be discussed together below. Particularly, FIGS. 5 and 6depict the flow of air 79 from the conduit 38 through a nozzle 42. Inthe depicted cross-sectional views, the inlet 72 of the nozzle 42 isjoined to the opening 70 to define a path by which air 79 flowing into acavity 76 (via inlet 40) defined by the conduit 38 is discharged fromthe nozzle 42 through the outlet 74 of the nozzle 42 as the output airflow 44 (FIG. 1). That is, the nozzle 42 includes a main body 89 havinga passage 73 extending therethrough, which is generally cylindrical inshape, but with a width or diameter that varies in accordance with thechanges in the inside diameter of an inside wall 82, as will bediscussed further below.

As will be appreciated, air flow naturally forms a radius or void whenflowing around sharp corners. This effect, which may be referred to ascornering, may result in losses in pressure and/or throughput as the airflows through certain nozzles. To compensate for such cornering effects,the depicted nozzle 42 may include a first section 78 and a secondsection 80. The first section 78, which may be referred to as a variablesection, has a variable or changing inside diameter (ID), represented byreference number 81. That is, the portion of the inside wall 82 that ispart of the variable section 78 may converge, such that the ID 81decreases as the inside wall 82 transitions away from the inlet 72. Thesecond section 80, which may be referred to as a resistive section, hasa generally constant ID, represented here by reference number 83, whichis generally less than the ID 81 at the inlet 72 of the nozzle 42. Thus,in the depicted embodiment, the inside wall 82 may gradually converge,such that the ID 81 gradually decreases beginning from the inlet 72along the length of the variable section 78 (e.g., moving towards theoutlet 74). At the point along the inside wall 82 where the ID 81 isapproximately equal to the ID 83, referred to here by reference number87 (e.g., a transition point), the resistive section 80 begins andextends for the remainder of the length of the nozzle 42, terminating atthe nozzle outlet 74. The dimensions of the nozzle 42 will be discussedbelow in more detail with respect to FIG. 7. As will also be discussedbelow, the section 80 is referred to as a resistive section because itis configured to control or restrict the air flow 79 after corneringeffects have been overcome or mitigated in the variable section 78.

By providing an entrance (e.g., inlet 72) having an ID that is greaterin diameter than the outlet ID (e.g., 83), the air flow 79 may stabilizeprior to reaching the resistive section 80. For instance, as shown inFIGS. 5 and 6, the air flow 79 entering the nozzle 42 flows over corners85 formed at the interface between the opening 70 and the inlet 72.However, due to cornering, the air flow 79 initially does not flowdirectly along or against (e.g., in contact with) the inside wall 82 ofthe nozzle upon entering from the inlet 72, as indicated by the annularspace 84. That is, the space 84 is considered to be annular due to theeffects of cornering, such that the air flow 79 generally does notinitially enter or flow through the annular space 84. As the air flow 79continues downstream towards the outlet 74, the annular space 84gradually decreases due to the convergence of the inside wall 82 in thevariable section 78 of the nozzle 42. This allows for the air flow 79 toovercome cornering effects that occur during the initial transition fromthe cavity 76 into the inlet 72 of the nozzle 42.

Because the nozzle 42 includes the variable section 78 that compensatesfor the effects of cornering, control of the output air flow 44 isprovided by the resistive section 80. That is, as the air flow 79reaches the transition point 87 between the variable section 78 and theresistive section 80, the annular space 84 is substantially reduces or,in some instances, terminated, such that the output air flow 44 iscontrolled or constricted by the ID 83 of the resistive section 80 andthus by the outlet 74 of the nozzle, as opposed to being limited due tocornering at the inlet 72.

FIGS. 3D, 3E, 3F, and 7 depict various views of an embodiment of thenozzle 42 and illustrate the dimensions of the nozzle 42 in more detail.As shown, the nozzle may have an overall length 88. The inlet 72 of thenozzle may have an outer diameter (OD) 90 and an inside diameter (ID)92. Thus, the variable ID 81 of the variable section 78 is equal to theinlet ID 92 when measured at the inlet 72. In certain embodiments, theID 92 may be approximately equal to the diameter 75 of the correspondingconduit 38 connected with the nozzle 42. By way of example, in certainembodiments, the inlet ID 92 and the diameter 75 of the conduit 38 mayboth be between approximately 0.5 to 2.5 inches (e.g., 0.5, 0.75, 1,1.25, 1.5, 1.75, 2 or 2.5 inches). The inlet OD 90 may be sized suchthat it is between approximately 20 to 50 percent greater than the inletID 92. For instance, in an embodiment where the inlet ID 92 and theopening 70 are each approximately 1 inch, the inlet OD 90 may be betweenapproximately 1.2 to 1.5 inches.

As the ID 81 of the variable section 78 transitions from the inlet 72 tothe transition point 87 (e.g., where the resistive section 80 begins),the ID 81 may decrease by between approximately 40 to 60 percent or, insome embodiments, between approximately 45 to 55 percent relative to theinlet ID 92. The ID 83 of the resistive section 80 may thus beapproximately equal to the ID 81 of the variable section 78 whenmeasured at the transition point 87. Accordingly, the ID 83 of theresistive section 80 may be between approximately 40 to 60 percent or,in some embodiments, between approximately 45 to 55 percent the lengthof the ID 92. By way of example only, in the above-mentioned embodimentwhere the ID 92 is approximately 1 inch, the ID 83 of the resistivesection 80 may be between approximately 0.4 to 0.6 inches or, morespecifically, between approximately 0.45 to 0.55 inches, or even morespecifically, approximately 0.5 inches. In embodiments, the relationshipbetween the inlet 72 and the outlet 74 may also be expressed in terms ofsurface area of their respective openings. For instance, in oneembodiment, the area of the outlet opening 74 may be betweenapproximately 15 to 40 percent or, more specifically, betweenapproximately 20 to 35 percent the area of the inlet opening 72.

As further shown, the variable section 78 may have a length 94, and theresistive section 80 may have a length 96. In the depicted embodiment,the length 94 of the variable section 78 is greater than the length 96of the resistive section 80. In other words, the distance along whichthe ID 81 converges is greater than the distance along which the ID 83remains generally constant. By way of example only, the length 96 of theresistive section 80, in one embodiment, may be between approximately 25to 45 percent (e.g., 25, 30, 35, 40, or 45 percent) or, morespecifically, between approximately 30 to 35 percent of the total length88 of the nozzle 42. Accordingly, the length 94 of the variable section78 may be expressed as the difference between the total length 88 of thenozzle 42 and the length 96 of the resistive section 80. For instance,based on the percentages provided above, the length 94 of the variablesection 78 may be between approximately 75 to 55 percent or, morespecifically, between approximately 70 to 65 percent the total length 88of the nozzle 42. By way of example only, in certain embodiments, thelength 88 of the nozzle may be between approximately 2 to 4 inches, andthe length 96 of the resistive section 80 may be between approximately0.625 to 1.8 inches. In one particular embodiment, the nozzle 42 mayhave an overall length 88 of approximately 2.5 inches with a resistivesection 80 having a length 96 of approximately 0.75 inches and avariable section 78 having a length 94 of approximately 1.75 inches.

As discussed above, the resistive section 80 has a generally constant ID83 along its length 96. Thus, the ID 100 of the outlet 74 isapproximately equal to the ID 83 of the resistive section 80. In thedepicted embodiment, the outside wall 86 may include a taper 99extending towards the outlet 74 of the nozzle 42, as shown in FIG. 7. Asshown, this may result in the OD 98 at the outlet 74 being less than theOD 90 of the inlet 72. By way of example only, in such an embodiment,the outlet OD 98 may be between approximately 60 to 80 percent (e.g.,60, 65, 70, 75, or 80 percent) of the inlet OD 90. Further, in someembodiments, the nozzle 42 may not include the taper 99, and thus theoutlet OD 98 may be approximately equal to the inlet OD 90.

The tip at the outlet 74 of the nozzle may include an annular wall 101(e.g., material between the inner wall 82 and the outer wall 86). Thethickness of the annular wall 101 at the outlet 74 is represented by thereference number 102. In certain embodiments, the thickness 102 may bebetween approximately 20 to 75 percent or, more specifically, betweenapproximately 20 to 50 percent of the outlet ID 100. By way of exampleonly, in one particular embodiment, the ID 92 may be approximately 1.25inches, the ID 100 may be approximately 0.5 inches, and the thickness102 may be between approximately 0.125 to 0.25 inches. The thickness102, when compared to certain nozzles, allows for the nozzle 42 to bemore rugged and durable against impacts that may occur in an industrialsetting, such as in the process system 10 of FIG. 1. This may prolongthe operational life of the nozzles 42 and thus the nozzle 42. Further,in the depicted embodiment, the outermost edge of the outlet 74 thatmeets the outside wall 86 may include a chamfer 104. In certainembodiments, the degree of the chamfer 104 may be between approximately30 to 60 degrees, between approximately 40 to 50 degrees, or betweenapproximately 42 to 48 degrees.

As mentioned above, in certain embodiments, the nozzle 42 may be formedfrom stainless steel, such as a piece of solid stainless steel barstock. For instance, the nozzle 42 may be manufactured by machiningand/or lathing the stainless steel bar stock. The resulting nozzle 42may be welded (e.g., by TIG welding) about an opening 70 on the conduit38 of the nozzle 42 to form a flow path through which air may bedischarged (e.g., as air output 44). Because the inlet 72 may include aradius cut (e.g., as shown in FIG. 4), the inlet 72 of the nozzle 42 mayconform against the outer surface of the conduit 38, which simplifiesthe welding process and thus reduces overall manufacturing time andcost. Further, because the nozzle 42 is welded to the conduit 38, theneed for additional fasteners and the like is reduced. Additionally,weld joints generally lack crevices in which bacterial growth may occur,which is ideal and beneficial for food and/or beverage applications.

With reference to FIGS. 3A, 3B, and 3C, the nozzle 42 may have anelongated cylindrical shaft 120 having a constant diameter d₁ connectedwith the outlet 74 of the nozzle 42. The elongated cylindrical shaft 120does not further compress the air flow through the nozzle 42, but rathermaintains the pressure of the air flow 44 at a relative constant. Theelongated cylindrical shaft 120 is used to guide the air flow 44 to anarticle 110 in order to orientate the article 110. Air flow 44 leavingthe nozzle 42 and the elongated cylindrical shaft 120 is preferablycapable of pushing articles 110 with between 0.75 and 1.50 Newtons offorce, and more preferably of about 1.10, ±0.25 Newtons of force. The byvarying the sizes of the ID 81 and the ID 83, the nozzle 42 is capableof receiving a low pressure air flow 44 from the air supply source 12 ata first velocity and outputting an air flow having a second velocitywhich is 4 to 16 times greater than the first velocity.

Preferably, the air supply source 12 may include a high flow centrifugalblower (“air blower”). By using a high flow centrifugal blower, airsource 12 is capable of generating an air flow 44 leaving the nozzle 42having the same amount of force as a compressor based air source, yetusing as much as 80% less energy. This results in an orientation device200 which his much more energy efficient than traditional orientationdevices.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

The invention claimed is:
 1. A method for orienting articles whichtravel along an assembly path within an air-driven orientation device,the method comprising: generating a low-pressure air flow using a highflow centrifugal blower of the air-driven orientation device;transmitting the low-pressure air flow through a conduit and to anozzle, wherein the nozzle has a nozzle inlet coupled with an outlet ofthe conduit, wherein the nozzle comprises a nozzle body having thenozzle inlet, a nozzle outlet, and an annular wall defining a firstpassage that extends through the nozzle body and which couples thenozzle inlet to the nozzle outlet; receiving the low pressure air flowat a first velocity at the nozzle inlet; and generating and outputtingan air flow having a second velocity at the nozzle outlet which is 4 to16 times greater than the first velocity, wherein the air flow havingthe second velocity is configured to orient articles.
 2. The method ofclaim 1 further comprising directing the air flow at articles whichtravel along an assembly path within the air-driven orientation devicein order to orient the articles.
 3. The method of claim 1, wherein thelow-pressure air flow has a pressure of between approximately 1-10pounds per square inch (psi) and a flow rate of between approximately50-2000 cubic feet per minute (CFM).
 4. The method of claim 1, whereinthe air flow output by the nozzle is used to position, convey, or alignarticles within the air-driven orientation device.
 5. The method ofclaim 1, further comprising strategically positioning multiple nozzleseach about the orientation device in order to orient articles whichtravel along an assembly path within the air-driven orientation device.6. The method of claim 1, wherein the nozzle includes an inside wallhaving a first section and a second section, wherein the first sectionhas a variable or changing first inside diameter (ID), wherein theportion of the inside wall that is part of the first section convergessuch that the first ID decreases as the inside wall transitions awayfrom the inlet, wherein the second section has a generally constantsecond ID which is generally less than the first ID at the inlet of thenozzle.
 7. The method of claim 6, wherein in the first section theinside wall gradually converges such that the first ID graduallydecreases beginning from the inlet along the length of the first sectionand moving towards the outlet, and wherein a transition point occurs ata point along the inside wall where the first ID is approximately equalto the second ID, and wherein the second section begins at thetransition point and extends for the remainder of the length of thenozzle, terminating at the nozzle outlet.